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ACTSYS Process Management Consultants Pte LtdACTSYS Process Management Consultants Pte Ltd

ISO50001 Barriers to Adoption by Industry

October 2016

1

ACTSYS Process Management Consultants Pte Ltd

Operator = Me

Energy Manager = My Wife

Energy Inefficiency = Not very visible

Energy Inefficiency KPI = # Pails/Day

Energy Audit = The Pail

Energy Planning = Wife’s household review

Putting pail in place

Setting KPI target

Energy Improvement = Repair Tap


ISO 50001 Energy Mgmt System

• Overview of Requirements– Based on the Plan-Do-Check-

Act continual improvement framework Plan: establish the objectives and

processes necessary to deliver results in accordance with opportunities to improve energy performance and the organization's policies

Do: implement the processes

Check: monitor and measure processes and product against policies, objectives and the key characteristics of its operations and report the results.

Act: take actions to continually improve energy performance.


Global Growth of ISO50001


High Growth Countries

• Germany– Energy intensive industries (>5 GWh/Y) minimum

requirement ISO50001 certification for energy tax incentives and partial exemption from renewable levies

– Mandatory Energy Audits

– 3500 ISO50001 certifications (2014)

• Sweden– Large Industries mandatory Energy Audits by certified

energy auditor

– Obligatory Implementation of certified Energy Management System


ISO50001 in Singapore

• Limited number of companies have gone for certification (<20)

• Common reasons

– Perception of limited benefits

– In-house Energy Management good enough

– Certification and verification generate high work load

– Audit fatigue from ISO9001, ISO14001


Sustaining Energy Performance

50%

40%

60%

30%

10%

10%

30%

70%

50%

30%

10%

30%

Energy Manager

Energy Plannning

Energy Measurement

Energy Reporting

Energy Targets

Energy Performance Indicators

Energy Deviation Monitoring

Energy Audits

Equipment Performance

Energy Improvement activities(Process and maintenance)

Energy Training

Continuous Improvement

ISO50001 EnMS Gap Analysis


Singapore ECA Findings

• Energy Conservation Act covered 213 energy intensive facilities

• Findings over 2 years of Reporting– Varying levels of rigour in Energy Management

– Low level of ambition in Energy Efficiency Improvement

– Room for improvement in Energy Efficiency

– 62% of Energy Performance of major systems not tracked

– Over 50% measured less than 1/3 of important parameters

Source : NEA


Actsys Observations

• Customer Segments

– Refineries

– Petrochemical Plants

– Pharmaceuticals

– Semiconductor

– Food Industry

• Energy Audits

• Measurement and Verifications

• Regular Performance Monitoring


Observation of Common Gaps

• Energy Planning (4.4)

– No Energy Reviews / Audits (4.4.3)

• Lack of internal capacity

• Not considered use of external Energy Auditors

• No structured plan for improvement

– No Energy Baseline (4.4.4)

• Not established without Energy Review

– Inadequate Energy Performance Indicators (4.4.5)

• Usually no Plant Wide EnPI (and no KPI targets)

• Not normalized for production levels or ambient conditions



• Implementation and Operation (4.5)

– Operational Control (4.5.4)

• No targets given to adjust for energy efficiency

• No criteria available to trigger maintenance for energy efficiency

– Design (4.5.6)

• Often farmed out to EPC contractors or Equipment Suppliers who do not place high priority on energy efficiency features



• Checking Performance (4.6)

– Measurement, Monitoring and Analysis (4.6.1)

• Insufficient instrumentation

• None or disparate data logging systems eg flows, temps on Scada and motor power on Motor Control Centre Panel

• Incomplete comprehension which operating parameters contribute to energy performance egChiller Condenser sub-cooling


Inconvenient Truth


Amine treating of Gas flows to

remove H2S, CO2 etc– Absorber column

– Regenerator column

Loss of Energy Efficiency– Excessive amine circulation

rates Pumping energy

Regenerator reboiler heat

– Regenerator Reboiler heat

Case Study - Absorber Optimization


Proposed

operating point Current operating

point

Case Study - Absorber Optimization


Energy Management Dashboards

• Enabler for ISO50001 integration into organization

• Many varieties commercially available

• Important features

– Plant Wide Energy KPI vs Target

– Drill down into plant subsections

– Drill down into equipment level operating parameters


Energy Consumption Dashboard


ISO50001 DashboardRefinery A

Overview Refinery EII 82 102.4

Crude Dis ti l ler Unit 1 CDU1 Delta +15.2

Crude Dis ti l ler Unit 2 CDU2 Delta -2.5

Naphtha Hydrotreater NHT Delta -4.1

Cont Catalytic Reformer CCR Delta +3.4

Gasoi l Hydrodesulphuriser GO HDS Delta +2.1

High Vacuum Unit HVU Delta -1.5

Hydrogen Manuf Unit HMU Delta -4.5

Hydrocracker HCU Delta +3.2

Delayed Coker Unit DCU Delta -2.8

Cogen Unit COGEN Delta +4.8

Uti l i ties UTILS Delta +7.1

30/7/2016 16:48Energy Performance Dashboard


Operational Dashboard

Refinery A

Actual Target Contribution to Refinery EII

Overview CDU 1 EII 155.1 122 +15.2

Crude Distiller Unit 1 CDU Intake m3/h 347.1 351 +1.0

Crude Distiller Unit 2 F101 Stack Temp DegC 288 285 +0.0

Naphtha Hydrotreater F101 Excess O2 % 2.4 1.8 +0.29

Cont Catalytic Reformer C101 Stripping Stm % 2.8 3 -1.15

Gasoil Hydrodesulphuriser C101 Pressure kg/cm2g 1.45 1.45 +0.0

High Vacuum Unit C119 Stripping Stm % 3.8 3 +2.3

Hydrogen Manuf Unit C103 Reboil Ratio kJ/kg 144 300 -2.1

Hydrocracker C102 Reboil Ratio kJ/kg 32 45 -0.3

Delayed Coker Unit C109 Reboil Ratio kJ/kg 486 300 +4.3

Cogen Unit C110 Reboil Ratio kJ/kg 137 140 -0.5

Utilities C110 Pressure kg/cm2g 8 8 +0.0

CDU Preheat Train HX UA

E137 kW/C 257 260 +0.0

E105A/B kW/C 52 116 +1.2

E139 kW/C 31 20 -0.1

E142A/B kW/C 106 212 +2.4

E108A/B kW/C 65 123 +3.5

E112A/B kW/C 180 220 +2.2

E141 kW/C 492 318 -0.24

E136 / E140 kW/C 120 300 +2.4

Energy Performance Dashboard 10/9/2016 12:02


Here’s why we need dashboards


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Nov-07 Jun-08 Dec-08 Jul-09 Jan-10 Aug-10 Feb-11 Sep-11 Apr-12 Oct-12 May-13

Ene

rgy

Co

st, R

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ESC

, mm

BTU

/MT

MTBE Energy Specific Consumption & Energy Cost (2008-2012)

Energy Cost

MTBE EnergySpecificConsumption

Savings

RM 2

Million/month

Case Study - Energy Index Dashboard


Learning Points from Others

• 3M 3M_Global.pdf

– EE program already in place 40 years

– ISO50001 gave tools for continuous improvement

– Implemented ISO50001 since 2011 in 18 facilities in 7 countries, they show EE improvement 60% more than group average

• Abbott Abbott.pdf

– Deciding Energy Performance Indicators and putting in place metering plan

– “We should have done it earlier”

3M_Global.pdf

Abbot.pdf



• JK Lakshmi Cement Ltd JK Lakshmi.pdf

– Many years of Energy Management activities but ISO50001 provided structure

– Smooth implementation of ISO50001 as staff already well versed with ISO9001 and ISO14001

– Challenge was to involve bottom line workmen

JK Lakshmi.pdf



• Nissan USA Nissan_USA.pdf

– “ISO50001 adds rigor, analysis, and gives good guidance. It’s one thing to have a target and objective, but ISO 50001 gives tools that empower you to be more disciplined and prove the impact certain activities have.” —Nissan North America Energy Team

– Some believed the company had already seized all opportunities to reduce energy usage; however, the EnMS and the EnPI tool enabled discovery of correctable, previously undetected energy losses.

Nissan_USA.pdf


Thank You

GT

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CONDENSER LOSS 33.53%

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www.actsys.com

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